Method and apparatus for manufacturing dry liners for pipe repair

ABSTRACT

A method of manufacturing a liner for reinforcing a pipe includes providing a continuous first reinforcing fibers extending in a first direction, moving the first reinforcing fibers in a machine direction such that the first direction is parallel to the machine direction, providing sheets of a material having second reinforcing fibers extending in a second direction, placing the sheets onto the moving first reinforcing fibers such that the second direction is substantially perpendicular to the first direction, and folding the sheets into a closed shape.

RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.16/343,872, filed on Apr. 22, 2019, which is the U.S. national stageentry of PCT/US2017/053374, filed on Sep. 26, 2017, which claimspriority to and all benefit of European Patent Application Serial No.16382498.0, filed on Oct. 31, 2016 and titled METHOD AND APPARATUS FORMANUFACTURING DRY LINERS FOR PIPE REPAIR, the entire disclosures ofwhich are fully incorporated herein by reference.

FIELD

The present application relates to liners for rehabilitating damaged ordeteriorated piping systems and to methods of manufacturing such liners.

BACKGROUND

Underground piping systems are essential for transporting liquids andgases to homes and businesses. Utilities typically use these pipingsystems for sewer, water, gas, and other applications. Such pipingsystems are installed several feet underground and access to the pipingsystems is therefore limited.

Underground pipes experience cyclical loading, premature wear,corrosion, porosity, and ambient foundation or earth movements. As aresult, pipes may develop damaged or weakened areas that require repair.To maintain the service afforded by the underground piping system, anycracks or leaks must be promptly detected and repaired. Repair of asmall section of the pipe by welding, patching, or otherwise is usuallyunsatisfactory and difficult because the pipe diameter does not allowhuman access in safe conditions. Likewise, digging up and replacing asection of pipe is difficult, expensive, and time consuming.

A solution for the repair of underground pipes is to repair a pipe whileit is still in place. Some in-situ pipe repair procedures include theinsertion of a pliable reinforcement liner into the damaged pipe. Thereare several types of reinforcement or reinforcing liners. Somereinforcement liners include glass fibers for support and strength.

The liner may be installed into the damaged pipe from one point of entryto another by one of several known techniques. The liner typically hasan outer diameter which is substantially the same as the inner diameterof the damaged pipe. The liner is pressurized so that it presses firmlyalong the inner wall of the damaged pipe. The expanded liner is thencured to form a new, rigid lining or surface within the original pipe.Liners that are hardened or cured after they have been installed arereferred to as “cured-in-place pipe (CIPP)” liners. The resin may becured by one of several known techniques, including UV curing.

Production methodologies for producing CIPP glass liners include afolding process. As shown in FIG. 1, in a conventional folding process,a liner 100 includes multiple layers of fabric 102, such as for example,woven roving mat fabrics, that are folded together with an overlap ofseveral centimeters per layer around an inner tubular film 104, such asfor example, a styrene tight tubular film. The liner 100 is then wrappedin an outer film 106, such as for example, a joint welded outer film.The number of fabric layers 102 depends on the required wall thickness.The liner 100 is also impregnated with a resin. To prevent prematurecuring of the resin, the impregnated liner is shielded from daylight/UVlight if resin being used is UV light curable or is shielded from hightemperatures if the resin used is hot curable.

Since the liner 100 has an outer diameter which is substantially thesame as the inner diameter of the damaged pipe, the width of the fabriclayers 102 must be customized for the diameter of pipe being repaired.Thus, liner manufacturers typically stock fabric layers with numerousdifferent widths in order to produce liners for different diameterpipes.

SUMMARY

The present application describes a method and apparatus formanufacturing a liner for reinforcing a pipe.

In an exemplary embodiment, the method includes providing a plurality ofcontinuous first reinforcing fibers extending in a first direction,moving the first reinforcing fibers in a machine direction such that thefirst direction is parallel to the machine direction, providing aplurality of sheets of a material having second reinforcing fibersextending in a second direction, placing the plurality of sheets ontothe moving first reinforcing fibers such that the second direction issubstantially perpendicular to the first direction, and folding theplurality of sheets into a closed shape.

The method and apparatus for manufacturing may be used to makepipe-reinforcing liners having different diameters. In an exemplaryembodiment, the method includes forming a first liner having a firstdiameter by providing a layer of continuous first reinforcing fibersextending in a first direction, moving the first reinforcing fibers in amachine direction such that the first direction is parallel to themachine direction, providing a supply of continuous material havingsecond reinforcing fibers extending in a second direction, thecontinuous material having a first width, cutting a plurality ofgenerally equal length, discrete sheets of the continuous material, thediscrete sheets having a first length, placing the plurality of sheetsonto the moving first reinforcing fibers such that the second directionis substantially perpendicular to the first direction, wherein each ofthe plurality of sheets partially overlaps one or more adjacent sheetsof the plurality of sheets, and folding the plurality of sheets into aclosed shape to form a first liner having a first diameter. A secondliner having a second diameter may be formed by providing a layer ofcontinuous first reinforcing fibers extending in a first direction,moving the first reinforcing fibers in a machine direction such that thefirst direction is parallel to the machine direction, providing a supplyof continuous material having second reinforcing fibers extending in asecond direction, the continuous material having the first width,cutting a plurality of generally equal length, discrete sheets of thecontinuous material, the discrete sheets having a second lengthdifferent than the first length, placing the plurality of sheets ontothe moving first reinforcing fibers such that the second direction issubstantially perpendicular to the first direction, and folding theplurality of sheets into a closed shape to form a first liner having asecond diameter.

Further features and advantages of the invention will become apparentfrom the following detailed description made with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and advantages of the generalinventive concepts, reference should be had to the following detaileddescription taken in connection with the accompanying drawings, inwhich:

FIG. 1 is a cross-sectional, perspective view of a conventional CIPPliner formed by a folding process;

FIG. 2 is a cross-sectional view of an exemplary embodiment of a CIPPliner;

FIG. 3 is schematic representation of an exemplary embodiment of anapparatus for manufacturing a CIPP liner;

FIG. 4 is a schematic representation of an exemplary embodiment of aside conveying system of the apparatus of FIG. 3;

FIG. 5 is a partial top view of the material on the apparatus of FIG. 3;

FIG. 6 is a flow chart of an exemplary embodiment of a process formanufacturing a CIPP liner with the apparatus of FIG. 3; and

FIG. 7 is a flow chart of an exemplary embodiment of a process formanufacturing CIPP liners having different diameters with the apparatusof FIG. 3.

DETAILED DESCRIPTION

While the general inventive concepts are susceptible of embodiment inmany different forms, there are shown in the drawings, and will bedescribed herein in detail, specific embodiments thereof with theunderstanding that the present disclosure is to be considered as anexemplification of the principles of the general inventive concepts.Accordingly, the general inventive concepts are not intended to belimited to the specific embodiments illustrated herein.

Unless otherwise defined, the terms used herein have the same meaning ascommonly understood by one of ordinary skill in the art encompassing thegeneral inventive concepts. The terminology used herein is fordescribing exemplary embodiments of the general inventive concepts onlyand is not intended to be limiting of the general inventive concepts. Asused in the description of the general inventive concepts and theappended claims, the singular forms “a,” “an,” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise.

The present application describes various exemplary methods andapparatus for forming a repair liner for reinforcing a pipe. In anexemplary embodiment, the method utilizes a modified folding process inwhich a single width reinforcing fabric can be used to manufactureliners with different diameters.

FIG. 2 illustrates a cross-section of an exemplary embodiment of a liner200 for rehabilitating a pipe. The liner 200 may be configured in avariety of ways. For example, different embodiments may includedifferent materials, have different diameters and thicknesses, and varyin the number of materials and number of layers used. In the exemplaryembodiment of FIG. 2, the liner 200 is illustrated as having an annularcross-section with an outer diameter OD and a thickness T. The liner200, however, is flexible prior to curing; thus, the liner 200 may befolded generally flat for storage or collapsed to a smallercross-section for insertion into a pipe. In addition, the outer diameterOD of the liner 200 may be expanded after insertion into a pipe.

In the exemplary embodiment, the liner 200 includes a layer of outerfoil 202, one or more layers of a first reinforcing material 204, aplurality of layers of a second reinforcing material 206, and a layer ofinner foil 208.

The outer foil layer 202 is configured to hold the first reinforcingmaterial in place relative to the second reinforcing material andprevent leakage of resin after the liner 200 has been impregnated. Theouter foil layer 202 may also provide shield the resin from daylight/UVlight to prevent a UV light curable resin from prematurely curing. Theouter foil layer 202 may be configured in a variety of ways. Forexample, the type of and number of materials used for the outer foillayer 202 may vary for different embodiments of the liner 200. Anymaterial capable of holding the first reinforcing material in placerelative to the second reinforcing material and preventing leakage ofresin may be used. Suitable materials for the outer foil layer 202include, but are not limited to, one or more of a polyamide,polypropylene, polyethylene, polyurethane, or polyester. In theexemplary embodiment, the outer foil layer 202 includes a polyamidelayer to act as a styrene barrier and a polyethylene layer to improvethe ability to weld the outer foil layer 202.

As illustrated, the outer foil layer 202 has a first half 209 and asecond half 210 opposite the first half. The first half 209 and thesecond half 210 are joined together along their respective edges to forma closed shape, such as a tube. The first half 209 and the second half210 may be joined in any suitable manner, such as for example, thermalwelding, ultrasonic binding, gluing, and taping.

The first reinforcing material 204 is positioned radially inward fromthe outer foil layer 202. The first reinforcing material 204 isconfigured to provide reinforcing support in a longitudinal direction ofthe liner 200. The first reinforcing material 204 may be configured in avariety of ways. For example, the type of and number of materials usedfor the first reinforcing material 204 may vary in differentembodiments. Any material suitable for use in a CIPP liner and capableof providing longitudinal reinforcement to the liner 200 may be used. Insome embodiments, the first reinforcing material 204 may be a pluralityof reinforcing fibers or may include reinforcing fibers that areincorporated into another material, such as a fabric. Suitable firstreinforcing materials 204 include, but are not limited to, one or moreof glass fiber rovings, such as T-30 glass, glass fiber fabrics that maybe woven, nonwoven, knitted, or stitched, glass fiber mats, or otherreinforcing fibers, or materials that contains fibers. The reinforcementfibers may be any type of organic or synthetic fibers. In some exemplaryembodiments, the reinforcement fibers include any one or more of glass,carbon, polyesters, polyolefins, nylons, aramids, poly(phenylenesulfide), polysulfone (PS), polyether sulfone (PES), polyacrilonitrile(PAN), silicon carbide (SiC), boron nitride, and the like. In someexemplary embodiments, the fabric (or layer) may be a hybrid fabric (orlayer) including multiple different types of fibers.

In the exemplary embodiment, the first reinforcing material 204 includesa plurality of continuous glass fibers oriented in a longitudinaldirection generally parallel to a longitudinal axis A of the liner 200.The glass fibers of the first reinforcing material 204 may be generallyevenly distributed around the circumference of the liner 200. In otherembodiments, however, the glass fibers of the first reinforcing material204 may not be evenly distributed. The number of glass fibers of thefirst reinforcing material 204 may vary in different embodiments of theliner 200. For example, a liner 200 with a larger outer diameter OD mayhave more glass fibers than a liner with a smaller outer diameter OD.

The second reinforcing material 206 is positioned radially inward fromthe first reinforcing material 204. The second reinforcing material 206is configured to provide reinforcing support in a radial direction ofthe liner 200. The second reinforcing material 206 may be configured ina variety of ways. For example, the type of and number of materials usedfor second reinforcing material 206 may vary in different embodiments.Any material suitable for use in a CIPP liner and capable of providingradial reinforcement to the liner 200 may be used. Suitable materialsfor the second reinforcing material 206 include, but are not limited to,one or more of glass fiber rovings, such as T-30 glass, glass fiberfabrics that may be woven, nonwoven, knitted, or stitched, glass fibermats, or other reinforcing fibers, or materials that contains fibers.

The second reinforcing material 206 may include reinforcement fibers.The second reinforcing material 206 may include any type of fibersuitable for providing desired structural qualities. The reinforcementfibers may be any type of organic or synthetic fibers. In some exemplaryembodiments, the reinforcement fibers include any one or more of glass,carbon, polyesters, polyolefins, nylons, aramids, poly(phenylenesulfide), polysulfone (PS), polyether sulfone (PES), polyacrilonitrile(PAN), silicon carbide (SiC), boron nitride, and the like. In someexemplary embodiments, the fabric (or layer) may be a hybrid fabric (orlayer) including multiple different types of fibers.

In the exemplary embodiment, the second reinforcing material 206includes sheets of oriented, continuous glass fibers. In otherembodiments, however, the second reinforcing material 206 could beinclude non continuous fibers, tapes or cut fabrics or mat. The glassfibers are oriented in a direction perpendicular to, or nearlyperpendicular to, the longitudinal axis A of the liner 200, thusproviding radial reinforcement to the liner. In the exemplaryembodiment, the formed liner 200 has continuous fibers oriented alongthe length of the liner and continuous fibers oriented substantiallyperpendicular to the length of the liner.

In the illustrated exemplary embodiment, the liner 200 includes a firstlayer 212 of the second reinforcing material layer 206 and a secondlayer 214 of the second reinforcing material 206. In other embodiments,however, the liner 200 may include more or less than two layers of thesecond reinforcing material 206. For example, the liner thickness T canbe modified by changing the number of layers of the second reinforcingmaterial 206. If a thicker liner 200 is desired, more layers of thesecond reinforcing material 206 can be used and vice versa.

As illustrated, the first layer 212 of the second reinforcing material206 has a first edge portion 216 and a second edge portion 218 oppositethe first edge portion 216. When the liner 200 is formed in the foldingprocess, the first edge portion 216 overlaps the second edge portion 218to allow the first and second edge portions 216, 218 to slide over eachother. Due to the ability of the first and second edge portions 216, 218to slide over each other, the liner 200 can expand to match the shape ofthe inner diameter of the pipe being rehabilitated.

Likewise, the second layer 214 of the second reinforcing material 206has a first edge portion 220 and a second edge portion 222 opposite thefirst edge portion 220. When the liner 200 is formed in the foldingprocess, the first edge portion 220 overlaps the second edge portion 222to allow the first and second edge portions 220, 222 to slide over eachother.

The inner foil layer 208 is configured to prevent leakage of resin andprovide a smooth inner surface while. The inner foil layer 208 may alsoserve as a styrene barrier. Furthermore, in some embodiments, the innerfoil layer 208 may be configured to allow UV light through the innerfoil layer to cure the resin. The inner foil layer 208 may be configuredin a variety of way. For example, the type of and number of materialsused for the inner foil layer 208 may vary in different embodiments. Anymaterial capable preventing leakage of resin, providing a smooth innersurface while, in some cases, allowing the UV light to cure the resinswhile providing a styrene vapor barrier may be used. Suitable materialsfor the inner foil layer 208 include, but are not limited to, one ormore of a polyamide, polypropylene, polyethylene, polyurethane, orpolyester. In the exemplary embodiment, the inner foil layer 208 and theouter foil layer 202 are the same material. In other embodiments,however, the inner foil layer 208 and the outer foil layer 202 mayinclude different materials.

FIG. 3 illustrates an exemplary embodiment of an apparatus 300 formanufacturing the liner 200 for rehabilitating a pipe. The apparatus 300includes a conveying system 302. The conveying system 302 can beconfigured in a variety of ways. Any system capable of supporting andmoving the layers of material used to form the liner 200, such as forexample, the outer and inner foil layers 202, 208, the first reinforcingmaterial 204, and the second reinforcing material 206, may be used. Theconveying system 302 may include, for example, one or more conventionalbelt conveyors. Any suitable conveyors, however, may be used. In theillustrated embodiment, the conveying system 302 includes a firstconveyor 304 and a second conveyor 306. In some embodiments, theconveying system 302 may include more or less than two conveyors.

The first conveyor 304 has a first end 310, a second end 312, and acontinuous belt 314 that moves along a top side 316 of the firstconveyor 304 in a machine direction B. Similarly, the second conveyor306 has a first end 320, a second end 322, and a continuous belt 324that moves along a top side 326 of the second conveyor 306 in a machinedirection B. In the exemplary embodiment, the first conveyor 304 and thesecond conveyor 306 are aligned end-to-end along a central longitudinalaxis C such that the second end 312 of the first conveyor 304 isadjacent the first end 320 of the second conveyor 306. As a result,material being carried in the machine direction B on the top side 316 ofthe first conveyor 304 will be transferred onto the top side 326 of thesecond conveyor 306 and be carried in the machine direction B by thesecond conveyor 306.

The apparatus 300 may include a first roll 330 of continuous outer foil202. The first roll 330 of continuous outer foil 202 is arrangedproximate the first end 310 of the first conveyor 304 such that a layerof the outer foil 202 is fed or drawn onto the top side 316 of the firstconveyor 304 and moved in the machine direction B. In the illustratedembodiment, the first roll 330 of continuous outer foil 202 ispositioned below the first end 310 of the first conveyor 304. In otherembodiments, however, the first roll 330 may be positioned in anysuitable location to allow a layer of the outer foil 202 to be fed ordrawn onto the top side 316 of the first conveyor 304. The layer ofouter foil 202 on the top side 316 of the first conveyor 304 serves asthe first half 209 of the outer foil layer 202 for the liner 200, asshown in FIG. 2. The first half 209 of the outer foil layer 202 has awidth W₁.

The apparatus 300 may include a first supply of the first reinforcingmaterial 204. The first supply of the first reinforcing material 204 maybe configured in a variety of ways. Any configuration that allows acontinuous supply of the first reinforcing material 204 to be arrangedon the first conveyor 304 in a manner that provides longitudinalreinforcement to the liner 200 may be used. In the exemplary embodiment,the supply of the first reinforcing material 204 includes a creel 330 orrack of spools of glass fibers.

The creel 330 is arranged such that a plurality of glass fibers is drawnfrom the creel 330 through a fiber guide 332 and under a guide roller333. The fiber guide 332 aligns the plurality of glass fibers into aplanar layer of generally parallel fibers 334. The planar layer ofgenerally parallel fibers 334 is deposited onto the outer foil 202 onthe top side 316 of the first conveyor 304. The planar layer ofgenerally parallel fibers 334 has a width W₂.

The apparatus 300 includes a movable side conveyor system 340. Themovable side conveyor system 340 is designed to deposit layers of secondreinforcing material 206 onto the first reinforcement material 204 at apredetermined and repeatable orientation. The movable conveyor system340 may be configured in a variety of ways. Any configuration capable ofdepositing layers of second reinforcing material onto the firstreinforcement material 204 at a predetermined and repeatable orientationmay be used.

Referring to FIGS. 3 and 4, in the exemplary embodiment, the movableside conveyor system 340 includes a side conveyor 342 mounted on amovable carriage 344. The side conveyor 342 includes a first end 346, asecond end 348, and a continuous belt 350 extending along a centrallongitudinal axis D (FIG. 3). The continuous belt 350 moves along a topside 352 of the side conveyor 342 in a machine direction E that issubstantially parallel to central longitudinal axis D and substantiallyperpendicular to the machine direction B of the first conveyor 304, asshown in FIG. 3. The second end 348 of the side conveyor 342 ispositioned such that material leaving the side conveyor 342 via thesecond end 348 will be placed on the top side 316 of the belt 314 of thefirst conveyor 304.

The movable side conveyor system 340 includes a roll 354, or othersuitable supply, of continuous second reinforcing material 206 carriedby the carriage 344. The roll 354 has a width W₃ (FIG. 3) and ispositioned proximate the first end 346 of the side conveyor 342 suchthat the second reinforcing material 206 is drawn or fed onto the belt350 and moved along the top side 352 of the side conveyor 342 in themachine direction E. In the illustrated embodiment, the roll 354 ispositioned above the first end 346 of the side conveyor 342. In otherembodiments, however, the roll 354 may be positioned in any suitablelocation to allow the second reinforcing material 206 to be drawn or fedonto the belt 350.

As indicated above, in the exemplary embodiment, the second reinforcingmaterial 206 includes oriented, continuous glass fibers. The roll 354 ofthe second reinforcing material 206 is configured such that the glassfibers are oriented substantially parallel to the central longitudinalaxis D and the machine direction E.

Referring to FIG. 4, the movable side conveyor system 340 includes acutter 356. The cutter 356 is designed to cut the continuous secondreinforcing material 206 into discrete sheets 358 of second reinforcingmaterial 206 having a length L and can be programmed or configured tocut the continuous second reinforcing material 206 at a desired time andin a repeatable manner. The cutter 356 may be configured in a variety ofways. Any device capable of cutting the continuous second reinforcingmaterial 206 into discrete lengths at a desired time and in a repeatablemanner may be used.

In the exemplary embodiment, the cutter 356 includes a knife edgepositioned proximate the first end 346 of the side conveyor 342. Thecutter 356 may extend perpendicular across the entire width W₃ (FIG. 3)of the second reinforcing material 206 such that the entire width W₃ ofthe second reinforcing material 206 can be cut at the same time.

The cutter 356 may be controlled in any suitable manner. For example, acontroller 360 may be programmed to control the operation of the sideconveyor system 340. The controller 360 may, for example, be linked toone or more of the cutter 356, the side conveyor 342, and the movablecarriage 344, and programmed to control the actuation of the cutter, thespeed of the side conveyor, and the movement of the carriage. Thecontroller 360, therefore, can actuate the cutter 356 at an appropriatetime to create discrete sheets 358 of second reinforcing material 206,each having a predetermined length. Further, the controller 360programming can be configured to readily modify the length L of thediscrete sheets 358 of second reinforcing material 206 in order toproduce a liner having a larger or smaller diameter. For example, thecontroller 360 can change when the cutter is actuated or change thespeed of the side conveyor 342 to produce discrete sheets 358 having adifferent length L. In this manner, the controller and cutterarrangement may modify the length of the discrete sheets 358 based onthe diameter of the liner being produced.

The movable carriage 344 can move the side conveyor 342 parallel to thecentral longitudinal axis C of the conveying system 302 while keepingthe machine direction E substantially perpendicular to the machinedirection B of the first conveyor 304. The movable carriage 344 can moveparallel to the central longitudinal axis C of the conveying system 302at a speed equal to the speed of the belt 314 of the first conveyor 304.In this manner, the discrete sheets 358 of second reinforcing material206 exiting the side conveyor 342 via the second end 348 may bedeposited onto the first conveyor 304 with the reinforcing fibersremaining substantially perpendicular to the fibers of the firstreinforcing material 204.

As illustrated in FIGS. 3 and 5, the movable conveyor system 340 candeposit discrete sheets 358 onto the first conveyor 304 such that eachof the plurality of discrete sheets 358 laterally overlaps, at leastpartially, one or more adjacent sheets of the plurality of sheets. Forexample, referring to FIG. 5, which illustrates only two of theplurality of discrete sheets 358 for simplicity, a first discrete sheet502 of second reinforcing material includes a first edge portion 504, asecond edge portion 506 substantially parallel to and opposite the firstedge portion 504, a third edge portion 508 substantially perpendicularto and extending between the first edge portion 504 and the second edgeportion 506, and a fourth edge portion 510 opposite the third edgeportion 508 and substantially perpendicular to and extending between thefirst edge portion 504 and the second edge portion 506. Likewise, asecond discrete sheet 512 of second reinforcing material includes afirst edge portion 514, a second edge portion 516 substantially parallelto and opposite the first edge portion 514, a third edge portion 518substantially perpendicular to and extending between the first edgeportion 514 and the second edge portion 516, and a fourth edge portion520 opposite the third edge portion 518 and substantially perpendicularto and extending between the first edge portion 514 and the second edgeportion 516.

As shown in FIG. 5, the second discrete sheet 512 may be placed at leastpartially over top of the first discrete sheet 502 such that the thirdedge portion 518 of the second discrete sheet 512 is offset a distanceX₁ from the third edge portion 508 of the first discrete sheet 502. Inaddition, the second discrete sheet 512 may be placed at least partiallyover top of the first discrete sheet 502 such that the second edgeportion 516 of the second discrete sheet 512 is offset a distance Y₁from the second edge portion 506 of the first discrete sheet 502. Thedistance X₁ and Y₁ can vary in different embodiments. For example, theoffset distance X₁ may be smaller for thicker liners and larger forthinner liners. Further, the distance Y₁ may be zero or may be adjustedfor liners with different diameters. For example, the distance Y₁ may belarger for larger diameter liners.

In some exemplary embodiments, the apparatus 300 may include one or moreadditional movable side conveyor systems (not shown) similar to the sideconveyor system 340. The one or more additional side conveyor systemsmay work cooperatively with the side conveyor system 340 to placediscrete sheets 358 of the second reinforcing material 206 onto thefirst conveyor 304. For example, the side conveyor system 340 and anadditional side conveyor system (not shown) may place alternatingdiscrete sheets 358 of the second reinforcing material 206 onto thefirst conveyor 304.

An additional side conveyor system (not shown) may be placed next to theside conveyor system 340 on the same side of the first conveyor 304.Both side conveyor systems may be programmed to move in unison with eachother. An additional side conveyor system (not shown) may also be placedon the opposite side of the first conveyor 304 as the first sideconveyor system 340 and programmed to work cooperatively with the sideconveyor system 340.

Referring to FIG. 3, the apparatus 300 may include a first roll 374 ofcontinuous inner foil 208. The first roll 374 of continuous inner foil208 is arranged downstream of the side conveyor 342 and rotatablysupported above the center of the first conveyor 304. The first roll 374of inner foil 208 is arranged such that a layer of the inner foil 208 isfed or drawn onto the top side 316 of the first conveyor 304 on top ofthe discrete sheets 358 of second reinforcing material 206 and is movedin the machine direction B. The inner foil 208 has a width W4.

Proximate the second end 312 of the first conveyor 304 is a foldingstation 376. The folding station 376 is designed to fold the discretesheets 358 of second reinforcing material 206 into a close-shapedconfiguration in which the edge portions of the discrete sheets overlap,such as for example, as discussed above regarding FIG. 2. Theclosed-shaped configuration may be, for example, a flattened, tubeshape, or any shape resulting from the sheet being folded over uponitself such that opposing edges overlap to form a closed shape.

The folding station 376 can be configured in a variety of ways. Anyapparatus or process capable of folding the discrete sheets 358 into aclose-shaped configuration 378 may be used. For example, in someembodiments the folding process may be accomplished manually. In otherembodiments, a folding mechanism (not shown) may be used to mechanicallyfold the edge portions of the discrete sheets in an overlapping manner.

In the illustrated embodiment, the first end 320 of the second conveyor306 is positioned adjacent the second end 312 of the first conveyor 304.The use of the second conveyor 306 provides, for example, an alternatelocation for application of the first half 209 of the outer foil layer202. In particular, similar to the first roll 330 of continuous outerfoil 202 arranged adjacent the first end 310 of the first conveyor 304,an alternate roll 380 of continuous outer foil 202 may be positionedproximate the first end 320 of the second conveyor 306 such that a layerof the outer foil 202 is fed or drawn onto the top side 326 of thesecond conveyor 306 under the first and second reinforcement materials204, 206 and moved in the machine direction B. In the illustratedembodiment, the alternate roll 380 of continuous outer foil 202 ispositioned below the first end 320 of the second conveyor 306. In otherembodiments, however, the alternate roll 380 may be positioned in anysuitable location to allow a layer of the outer foil 202 is fed or drawnonto the top side 326.

The apparatus 300 may include a second supply of continuous firstreinforcing material 204. The second supply of continuous firstreinforcing material 204 may be configured in a variety of ways. Anyconfiguration that allows a supply of continuous first reinforcingmaterial 204 to be arranged on the folded configuration 378 of thesecond reinforcing material 206 in a manner that provides longitudinalreinforcement may be used. In the exemplary embodiment, the secondsupply of the first reinforcing material 204 is arranged substantiallysimilarly to the first supply of first reinforcing material. The secondsupply includes a creel 384 or rack of spools of T-30 glass fibers.

The creel 384 is arranged such that a plurality of T-30 glass fibers isdrawn from the creel 384 through a fiber guide (not shown) and under aguide roller 386. The fiber guide (not shown) aligns the plurality ofT-30 glass fibers into a planar layer of generally parallel fibers 388.The planar layer of generally parallel fibers 388 are deposited onto thefolded configuration 378 of the second reinforcing material 206. Theplanar layer of generally parallel fibers 388 has a width W₅.

The apparatus 300 may include a second roll 390 of continuous outer foil202. The second roll 390 of continuous outer foil 202 is arranged abovethe top side 326 of the second conveyor 306 such that a layer of theouter foil 202 is fed or drawn onto the material on the top side 326 ofthe second conveyor 306 downstream of the creel 384 and moved in themachine direction B. The layer of outer foil 202 from the second roll390 serves as the second half 210 of the outer foil layer 202 for theliner 200 (FIG. 2). The second half 210 of the outer foil layer 202 hasa width W₆.

Proximate to the second roll 390 of continuous outer foil 202 is asealing station 392. Referring to FIGS. 2 and 3, the sealing station 396is designed to attach the first half 209 of the outer foil 202 to thesecond half 210 of the outer foil 202 along lateral edges 394, 396 ofthe liner 200. The sealing station 392 can be configured in a variety ofways. Any apparatus or process capable of attaching the first half 209of the outer foil 202 to the second half 210 of the outer foil 202 alongthe lateral edges 394, 396 of the liner 200 may be used. The first half209 of the outer foil 202 and the second half 210 of the outer foil 202may be attached along the lateral edges 394, 396 in any suitable manner,such as for example, heat sealing, binding, taping, or gluing.

FIG. 6 illustrates a flow diagram of an exemplary method 600 of formingthe liner 200. The exemplary method 600 is continuous, in that two ormore continuous materials are combined to form a continuous liner. Themethod 600 includes providing a plurality of continuous firstreinforcing fibers extending in a first direction 602 and moving thefirst reinforcing fibers in a machine direction such that the firstdirection is parallel to the machine direction 604. The method alsoincludes providing a plurality of sheets of a material having secondreinforcing fibers extending in a second direction 606. While the firstmaterial is moved in the machine direction, the plurality of sheets of asecond material are placed onto the moving first reinforcing fibers suchthat the second direction is substantially perpendicular to the firstdirection 608. Each of the plurality of sheets may also partiallyoverlap, in the machine direction, one or more adjacent sheet of theplurality of sheets.

After the plurality of sheets of a second material are placed onto themoving first reinforcing fibers, the plurality of sheets are folded intoa closed shape 610. For example, the opposing longitudinal edges of eachof the plurality of sheets of the second material are folded toward thecenter of each of the sheets such that the edges overlap forming aclosed shape, such as a flattened tube. Referring to FIG. 5, as example,the first edge 506 and the second edge 504 of the first discrete sheet502 are folded toward the center of each of the first discrete sheet 502such that the edges overlap forming a closed shape. Thus, the discretesheets are folded in, or parallel to the second direction.

Additional continuous first material having reinforcing fibers in afirst direction may be provided and positioned on top of the closedshape. During the manufacturing process an inner foil layer may bepositioned such that the inner foil layer forms the inner surface of theclosed shape and an outer foil layer may be positioned such that theouter foil layer surrounds the first material and the second material.

FIG. 7 illustrates a flow diagram of an exemplary method 700 of formingtwo or more liners having different diameters. The method 700 of FIG. 7may be substantially similar to the method 600 of FIG. 6 to form aliner. However, to form a second liner having a different diameter thana first liner, the length of the discrete sheets of the secondreinforcing material is changed. For example, to form a liner with alarger diameter or a smaller diameter than the first liner, the lengthof the discrete sheets of the second reinforcing material is increasedor decreased, respectively. The exemplary method 700 is continuous, inthat two or more continuous materials are combined to form a continuousliner.

In particular, the method 700 includes forming a first liner having afirst diameter by providing a plurality of continuous first reinforcingfibers extending in a first direction 702 and moving the firstreinforcing fibers in a machine direction such that the first directionis parallel to the machine direction 704. The method 700 also includesproviding a supply of continuous material having second reinforcingfibers extending in a second direction, the continuous material having afirst width 706. The supply of continuous material is then cut into aplurality of generally equal length, discrete sheets of the continuousmaterial, the discrete sheets having a first length 708. While the firstmaterial is moved in the machine direction, the plurality of cut sheetsof the second material are placed onto the moving first reinforcingfibers such that the second direction is substantially perpendicular tothe first direction 710. Each of the plurality of sheets may alsopartially overlap, in the machine direction, one or more adjacent sheetof the plurality of sheets.

After the plurality of sheets of a second material are placed onto themoving first reinforcing fibers, the plurality of sheets are folded intoa closed shape 712. For example, the opposing longitudinal edges of eachof the plurality of sheets of the second material are folded toward thecenter of each of the sheets such that the edges overlap forming aclosed shape, such as a flattened tube. Additional continuous firstmaterial having reinforcing fibers in a first direction may be providedand positioned on top of the closed shape. During the manufacturingprocess an inner foil layer may be positioned such that the inner foillayer forms the inner surface of the closed shape and an outer foillayer may be positioned such that the outer foil layer surrounds thefirst material and the second material.

To form a second liner having a second diameter, the steps are repeatedbut when the supply of continuous material is cut into a plurality ofgenerally equal length, discrete sheets of the continuous material, thediscrete sheets are cut to a second length that is different than thefirst length. In this way, when the discrete sheets having a secondlength are folded into a closed shape to form a liner, the liner willhave a different diameter than the liner formed from the discrete sheetshaving a first length. Thus, the width of the discrete sheets is notchanged to manufacture liners having different diameters. Instead, thelength of the discrete sheets is adapted to provide the desired diameterfor the liner once the material is folded.

In particular, the method 700 further includes forming a first linerhaving a second diameter by providing a plurality of continuous firstreinforcing fibers extending in a first direction 714 and moving thefirst reinforcing fibers in a machine direction such that the firstdirection is parallel to the machine direction 716. The method 700 alsoincludes providing a supply of continuous material having secondreinforcing fibers extending in a second direction, the continuousmaterial having a first width 718. The supply of continuous material isthen cut into a plurality of generally equal length, discrete sheets ofthe continuous material, the discrete sheets having a second length 720.While the first material is moved in the machine direction, theplurality of cut sheets of the second material are placed onto themoving first reinforcing fibers such that the second direction issubstantially perpendicular to the first direction 722. Each of theplurality of sheets may also partially overlap, in the machinedirection, one or more adjacent sheet of the plurality of sheets. Afterthe plurality of sheets of a second material are placed onto the movingfirst reinforcing fibers, the plurality of sheets are folded into aclosed shape 724.

In some embodiments of the method, the widths W₁, W₆ of the outer foillayers, the widths W₂, W₅ of the planar layers of the first reinforcingfibers, and the width W₄ of the inner foil layer may also be modifiedwhen making a liner having a different diameter than the first liner. Inother embodiments, however, the widths of the outer and inner foillayers and the planar layers of the first reinforcing fibers need not bemodified.

Other Variations

Other variations of exemplary embodiments of the method and apparatusfor manufacturing a liner for reinforcing a pipe are described below.

[A] A method of manufacturing a liner for reinforcing a pipe, the methodcomprising: providing a plurality of continuous first reinforcing fibersextending in a first direction; moving the first reinforcing fibers in amachine direction such that the first direction is parallel to themachine direction; providing a plurality of sheets of a material havingsecond reinforcing fibers extending in a second direction; placing theplurality of sheets onto the moving first reinforcing fibers such thatthe second direction is substantially perpendicular to the firstdirection; and folding the plurality of sheets into a closed shape.

[B] The method of [A] wherein providing the plurality of sheets furthercomprises cutting a supply of continuous material having secondreinforcing fibers into discrete sheets.

[C] The method of [B] wherein cutting the supply of continuous materialhaving second reinforcing fibers into discrete sheets is performedproximate a conveyor that places the plurality of sheets onto the firstreinforcing fibers.

[D] The method of [C] wherein the supply of continuous material havingsecond reinforcing fibers and the conveyor are mounted on a movablecarrier that is movable parallel to the machine direction.

[E] The method of [B or C] wherein the continuous material having secondreinforcing fibers has a width, and wherein cutting the supply ofcontinuous material having second reinforcing fibers into discretesheets further comprises modifying the length of the discrete sheetsbased on the diameter of the liner being produced while maintaining thewidth of the continuous material.

[G] The method of any one of [A-E] wherein the continuous firstreinforcing fibers are glass fibers.

[H] The method of anyone of [A-G] further comprising providing aplurality of continuous third reinforcing fibers extending in the firstdirection onto the folded plurality of sheets.

[I] The method of any one of [A-H] further comprising providing acontinuous foil layer onto the plurality of sheets prior to folding theplurality of sheets.

[J] The method of any one of [A-I] wherein the second reinforcing fibersare oriented, continuous glass fibers.

[K] The method of any one of [A-J] wherein placing the plurality ofsheets onto the moving first reinforcing fibers further comprises atleast partially overlapping each of the plurality of sheets with one ormore adjacent sheets of the plurality of sheets.

[L] The method of any one of [A-K] wherein placing the plurality ofsheets onto the moving first reinforcing fibers further comprises movingthe plurality of sheets onto the first reinforcing fibers with aconveyor while moving the conveyor in the machine direction.

[M] The method of any one of [L] wherein the first reinforcing fibersare moved at a first speed in the machine direction and the conveyor ismoved at substantially the same speed.

[N] A method of manufacturing pipe-reinforcing liners having differentdiameters, the method comprising: (a) forming a first liner having afirst diameter by: providing a layer of continuous first reinforcingfibers extending in a first direction; moving the first reinforcingfibers in a machine direction such that the first direction is parallelto the machine direction; providing a supply of continuous materialhaving second reinforcing fibers extending in a second direction, thecontinuous material having a first width; cutting a plurality of equallength, discrete sheets of the continuous material, the discrete sheetshaving a first length; placing the plurality of sheets onto the movingfirst reinforcing fibers such that the second direction is substantiallyperpendicular to the first direction, wherein each of the plurality ofsheets partially overlaps one or more adjacent sheets of the pluralityof sheets; folding the plurality of sheets into a closed shape to form afirst liner having a first diameter; and (b) forming a second linerhaving a second diameter by: providing a layer of continuous firstreinforcing fibers extending in a first direction; moving the firstreinforcing fibers in a machine direction such that the first directionis parallel to the machine direction; providing a supply of continuousmaterial having second reinforcing fibers extending in a seconddirection, the continuous material having the first width; cutting aplurality of equal length, discrete sheets of the continuous material,the discrete sheets having a second length different than the firstlength; placing the plurality of sheets onto the moving firstreinforcing fibers such that the second direction is substantiallyperpendicular to the first direction; and folding the plurality ofsheets into a closed shape to form a second liner having a seconddiameter.

[O] The method of [N] wherein cutting a plurality of equal length,discrete sheets of the continuous material is performed proximate aconveyor that places the plurality of sheets onto the first reinforcingfibers.

[P] The method of claim [O] wherein the supply of continuous materialhaving second reinforcing fibers and the conveyor are mounted on amovable carrier that is movable parallel to the machine direction.

[Q] The method of [P] further comprising a cutter that cuts thecontinuous material having second reinforcing fibers into a plurality ofequal length, discrete sheets, wherein the cutter is mounted on themovable carrier.

[R] The method of any one of [N-Q] wherein the continuous firstreinforcing fibers are glass fibers.

[S] The method of any one of [N-R] further comprising providing acontinuous foil layer onto the plurality of sheets prior to folding theplurality of sheets.

[T] The method of any one of [N-S] wherein the second reinforcing fibersare oriented, continuous glass fibers.

[U] The method of any one of [N-T] wherein placing the plurality ofsheets onto the moving first reinforcing fibers further comprises atleast partially overlapping each of the plurality of sheets with one ormore adjacent sheets of the plurality of sheets.

[V] The method of any one of [N-U] wherein placing the plurality ofsheets onto the moving first reinforcing fibers further comprises movingthe plurality of sheets onto the first reinforcing fibers with aconveyor and moving the conveyor in the machine direction while placingthe plurality of sheets onto the moving first reinforcing fibers.

[W] The method of any one of [N-V] wherein the first reinforcing fibersare moved at a first speed in the machine direction and the conveyor ismoved at substantially the same speed.

[X] An apparatus for manufacturing a liner for reinforcing a pipe, theapparatus comprising: a supply of continuous first reinforcing fibersfor being moved in a first machine direction; a first conveyor having aconveyor belt capable of moving the continuous first reinforcing fibersin the first machine direction; a side conveyor system movable relativeto the first conveyor, the side conveyor system comprising: a supply ofcontinuous second reinforcing material having second reinforcing fibersextending in a second machine direction that is perpendicular to thefirst machine direction; a side conveyor having a conveyor belt that iscapable of moving the second reinforcing material in the second machinedirection; and a cutter that cuts the continuous second reinforcingmaterial into discrete sheets of second reinforcing material, whereinthe side conveyor is operable to place the discrete sheets onto thecontinuous first reinforcing material on the first conveyor such thatthe second reinforcing fibers are substantially perpendicular to thefirst reinforcing fibers.

[Y] The apparatus of [X] wherein the side conveyor system moves in thefirst machine direction while placing the plurality of sheets onto themoving first reinforcing fibers.

[Z] The apparatus of [Y] wherein the first conveyor moves the firstreinforcing fibers at a first speed in the first machine direction andthe side conveyor system moves in the machine direction at substantiallythe same speed.

[AA] The apparatus any one of [X-Z] wherein the continuous firstreinforcing fibers are glass fibers.

[BB] The apparatus of any one of [X-AA] further comprising a foldingstation for folding the plurality of sheets into a closed shape.

[CC] The apparatus of any one of [X-BB] further comprising a secondsupply of continuous first reinforcing fibers extending in a firstmachine direction, the second supply positioned to place continuousfirst reinforcing fibers onto the plurality of sheets after the sheetsare folded into the closed shape.

[DD] The apparatus of any one of [X-CC] further comprising a controllerthat controls the side conveyor system, the controller adapted to modifythe length of the discrete sheets based on the diameter of the linerbeing produced.

While various inventive aspects, concepts, and features of the generalinventive concepts are described and illustrated herein in the contextof various exemplary embodiments, these various aspects, concepts, andfeatures may be used in many alternative embodiments, eitherindividually or in various combinations and sub-combinations thereof.Unless expressly excluded herein all such combinations andsub-combinations are intended to be within the scope of the generalinventive concepts. Still further, while various alternative embodimentsas to the various aspects, concepts, and features of the inventions(such as alternative materials, structures, configurations, methods,circuits, devices and components, software, hardware, control logic,alternatives as to form, fit and function, and so on) may be describedherein, such descriptions are not intended to be a complete orexhaustive list of available alternative embodiments, whether presentlyknown or later developed. Those skilled in the art may readily adopt oneor more of the inventive aspects, concepts, or features into additionalembodiments and uses within the scope of the general inventive conceptseven if such embodiments are not expressly disclosed herein.Additionally, even though some aspects, concepts, or features of theinventions may be described herein as being a preferred arrangement ormethod, such description is not intended to suggest that such feature isrequired or necessary unless expressly so stated. Still further,exemplary or representative values and ranges may be included to assistin understanding the present disclosure; however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Moreover, whilevarious aspects, concepts, and features may be expressly identifiedherein as being inventive or forming part of an invention, suchidentification is not intended to be exclusive, but rather there may beinventive aspects, concepts and features that are fully described hereinwithout being expressly identified as such or as part of a specificinvention. Descriptions of exemplary methods or processes are notlimited to inclusion of all steps as being required in all cases, nor isthe order that the steps are presented to be construed as required ornecessary unless expressly so stated.

What is claimed is:
 1. An apparatus for manufacturing a liner forreinforcing a pipe, the apparatus comprising: a supply of continuousfirst reinforcing material having first reinforcing fibers extending ina first machine direction; a first conveyor having a first conveyor beltcapable of moving the continuous first reinforcing material in the firstmachine direction; a second conveyor system movable relative to thefirst conveyor, the second conveyor system comprising: a supply ofcontinuous second reinforcing material having second reinforcing fibersextending in a second machine direction that is perpendicular to thefirst machine direction; a second conveyor having a second conveyor beltthat is capable of moving the second reinforcing material in the secondmachine direction; and a cutter that cuts the continuous secondreinforcing material into discrete sheets of second reinforcingmaterial; wherein the second conveyor is operable to place the discretesheets onto the continuous first reinforcing material on the firstconveyor such that the second reinforcing fibers are perpendicular tothe first reinforcing fibers.
 2. The apparatus of claim 1, wherein thesecond conveyor system moves in the first machine direction whileplacing the plurality of discrete sheets onto the moving firstreinforcing material.
 3. The apparatus of claim 2, wherein the firstconveyor moves the first reinforcing material at a first speed in thefirst machine direction and the second conveyor system moves in themachine direction at substantially the same speed.
 4. The apparatus ofclaim 1, wherein the continuous first reinforcing fibers are glassfibers.
 5. The apparatus of claim 1, further comprising a foldingstation for folding the plurality of discrete sheets into a closedshape.
 6. The apparatus of claim 5, further comprising a second supplyof continuous first reinforcing fibers extending in a first machinedirection, the second supply of continuous first reinforcing fibersbeing positioned to place the continuous first reinforcing fibers ontothe plurality of discrete sheets after the plurality of discrete sheetsare folded into the closed shape.
 7. The apparatus of claim 5, furthercomprising a supply of a continuous foil positioned to place a foillayer onto the plurality of sheets before the plurality of discretesheets are folded into the closed shape.
 8. The apparatus of claim 1,further comprising a controller that controls the second conveyorsystem, the controller adapted to modify the length of the discretesheets based on the diameter of the liner being produced.
 9. Theapparatus of claim 1, wherein the second reinforcing fibers areoriented, continuous glass fibers.
 10. The apparatus of claim 1, whereinthe second conveyor places the discrete sheets onto the continuous firstreinforcing material on the first conveyor such that each discrete sheetpartially overlaps with one or more adjacent discrete sheets.
 11. Theapparatus of claim 1, wherein the second conveyor is mounted on amovable carrier that is movable parallel to the first machine direction.